Thermal break air-conditioner tank

ABSTRACT

The present invention relates to a thermal bridge break air-conditioner tank, comprising a framework and a wall panel, wherein the framework is assembled from three-ways connectors, rims, and a middle beam assembly, the three-ways connectors and the rims being plastically integrally formed structures; a thermal bridge break structure made of a PVC material is connected to outer sides of the three-ways connectors and the rims; the framework is formed as a cubic structure; the wall panel is assembled from a panel and a plurality of external sheet metal parts, and the wall panel is disposed in the framework by shape-fitting. The air-conditioner tank according to the present invention has a good thermal bridge break performance, and meanwhile simplifies the assembling and connecting between component.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No. 15/608,768, filed May 30, 2017, entitled “THERMAL BREAK AIR-CONDITIONER TANK,” which claims priority to and the benefit of Chinese Application No. 201620519850.7, filed May 31, 2016, entitled “THERMAL BRIDGE BREAK AIR-CONDITIONER TANK,” which are incorporated by reference herein in their entirety.

FIELD OF THE INVENTION

The present invention generally relates to an air-conditioning apparatus, and more particularly to a thermal bridge break air-conditioner tank.

BACKGROUND OF THE INVENTION

An air-conditioner tank delivers treated cold or warm air over a long distance to respective air-conditioned spaces through a high static pressure fan or a high air volume fan. Due to the large size of tank and the large temperature difference between inside and outside the tank, there are thorny issues in terms of tank structure strength, noise insulation, anti-condensation, sheet metal manufacturing, and assembly of the tank, etc.

In the prior art, an air-conditioner tank usually employs an aluminum alloy framework structure, i.e., employing a rim integrally formed by an aluminum profile. The rim also functions to fix a foamed panel and internal parts. Because the aluminum profile has a good heat conductivity, cold energy inside the tank is easily conducted to an outer wall of the aluminum profile through the aluminum profile itself, causing leakage of cold energy. Meanwhile, due to a large and complex cross-section of rims of the aluminum profile, the manufacturing cost is high Rims are usually connected via a coupling piece that is easily deformable, which will influence the perpendicularity and parallelism of a body framework and will further cause uneven interstices between the body framework and the foamed panel tank, making it difficult to assemble.

Further, in the prior art, the foamed panel of the air-conditioner tank is secured using aluminum strips and adhesive tapes, such that the tank as a whole cannot bear a heavy load and the installation is cumbersome; moreover, because the interstices between panels are decorated by trim strips, the appearance of the whole tank is unpleasing.

SUMMARY OF THE INVENTION

The present invention provides a thermal bridge break air-conditioner tank to at least partially solve the above problems existing in the prior art.

According to a first aspect of the present invention, there is provided a thermal bridge break air-conditioner tank, comprising a framework and a wall panel, wherein the framework is assembled from three-ways connectors, rims, and a middle beam assembly, the three-ways connectors and the rims being plastically integrally formed structures; a thermal bridge break structure made of a PVC material is connected to outer sides of the three-ways connectors and the rims; the framework is formed as a cubic structure; the wall panel is assembled from a panel and a plurality of external sheet metal parts, and the wall panel is fitted in the framework by shape-fitting.

According to the present invention, the connector is designed as three-ways connector integrally formed by a high strength plastic material; by interference fitting the three-ways connector and the rim profiles, a thermal bridge break is achieved, and the body framework assembled from the three-ways connector and the rim profiles has a better rigidity and a small deformation.

Optionally, the three-ways connectors and the rims are interference fitted by convex ribs.

Optionally, the three-ways connectors and the rims are interference fitted by a plurality of protrusion parts that are provided on the three-ways connector.

Optionally, the rim includes an inner aluminum alloy framework and an outer thermal bridge break structure, the thermal bridge break structure being snap-fitted to the aluminum alloy framework.

Optionally, the snap-fit is a dovetail structure or a hook-shaped structure.

Optionally, the rim is formed as a stepped structure, and the wall panel is formed as a stepped panel shape-fitting with the stepped structure.

Optionally, the stepped panel includes a convex portion at a center and a quadrangular convex ring at a periphery, the convex ring being fit with the stepped structure of the rim.

Optionally, the middle beam assembly comprises a middle beam connector and a middle profile interference-fitted with the middle beam connector, wherein the middle beam connector being secured to the rim via a built-in fastener.

BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS

The above and other aspects of the present invention will become more apparent and easier to understand from the following description of the exemplary embodiments of the present invention in conjunction with the accompanying drawings. In the accompanying drawings:

FIG. 1 schematically illustrates an embodiment of a three-ways connector of the present invention;

FIG. 2 schematically illustrates a thermal bridge break and a rim of the present invention;

FIG. 3 schematically illustrates a middle beam connector of the present invention;

FIG. 4 schematically illustrates a middle beam profile of the present invention;

FIG. 5 schematically illustrates a sectional view of a foamed panel of the present invention;

FIG. 6 schematically illustrates an exploded view of a foamed panel of the present invention;

FIG. 7 schematically illustrates a schematic diagram of a tank framework of the present invention;

FIG. 8 schematically illustrates a diagram of assembling a three-ways connector and rims of the present invention;

FIG. 9 schematically illustrates a diagram of assembling a middle beam connector and a middle beam of the present invention;

FIG. 10 schematically illustrates a diagram of assembling a rim and a middle beam of the present invention;

FIG. 11 schematically illustrates a diagram of assembling a panel and a framework of the present invention;

FIG. 12 schematically illustrates another embodiment of a three-ways connector of the present invention;

FIG. 13 schematically illustrates a further embodiment of a thermal bridge break and a rim of the present invention;

FIG. 14 schematically illustrates a still further embodiment of a thermal bridge break and a rim of the present invention;

FIG. 15 schematically illustrates another embodiment of a foamed panel.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Hereinafter, the preferred embodiments of the present invention will be illustrated with reference to the accompanying drawings. It needs to be noted that the terms “up,” “down,” “front,” “rear,” “left,” “right” and similar expressions used herein are only for illustrative purposes, not for limiting.

FIG. 1 illustrates a plastic three-ways connector 1 of the present invention, wherein the connector 1 for example may be injection molded with PA66 doping with 10% glass fiber. As shown in the figure, the three-ways connector 1 is a hollow body having protrusions formed in three axial directions of X, Y, and Z, respectively, wherein the protrusions are preferably convex ribs having a width of 1.0 mm and a height of 0.4 mm, and a side of the respective convex rib is formed as an L-shape matching with the cross-section of the rim profile. With the convex ribs, the three-ways connector 1 is more easily interference-fitted with the rim profile.

FIG. 2 shows a thermal bridge break aluminum alloy rim profile according to the present invention. The rim profile comprises an external thermal bridge break 1-1 made of a PVC material and an internal aluminum alloy rim 1-2. Preferably, these two parts are both formed by an extrusion process. A recessed groove is provided on an outer side edge of the aluminum alloy framework 1-2; a hook-shaped piece is provided on a corresponding position at an inner side of the thermal bridge break 1-1, wherein the thermal bridge break 1-1 is shape-fitting with the aluminum alloy framework 1-2 by the hook-shaped piece.

FIGS. 3-4 illustrate a middle beam connector 2 and a middle beam profile 4 according to the present invention, wherein the middle beam connector 2 is preferably made of a plastic material, one end of the middle beam connector 2 has a side mounting space for being connected to the framework structure; preferably, the middle beam connector 2 is secured to the framework by a built-in fastener, and the other end of the middle beam connector 2 has a protrusion extending along an axial direction, wherein the protrusion is preferably a protrusion having a width of 1.0 mm and a height of 0.4 mm; a side face of the protrusion forms a rectangle matching with a rectangular cross section of the middle beam profile 4; by means of the protrusion, the middle beam connector 2 is more easily interference-fitted with the middle beam profile 4. The middle beam profile 4 is preferably a rectangular middle beam formed by an aluminum alloy through an extrusion process.

FIGS. 5-6 show a foamed panel 3 according to the present invention. As shown in the figure, the foamed panel 3 is preferably a PU (Polyurethane) foamed panel. The panel includes a closed body comprising an outer panel 3 a preferably made of a sheet metal part, an inner panel 3 b preferably made of a sheet metal part, and a PVC frame strip 3 c that connects the inner panel and the outer panel. After the PU 3 d of a predetermined density is injected in the closed body, a complete PU foamed panel 3 is formed. As shown in FIG. 5, the PVC frame strip 3 c forms a stepped portion at a side face of the panel, and the foamed panel 3 may be assembled to the framework using the stepped portion. Because the panel adopts a stepped portion design, a complete quadrilateral convex ring is formed at a periphery of the panel, thereby effectively compressing the sealing strip adhered to the rim profile and the middle beam profile, thereby enhancing the sealing performance of the tank.

FIG. 7 illustrates a thermal bridge break air-conditioner tank according to the present invention, wherein the tank comprises a framework and a wall panel (not shown in the figure), wherein the framework is assembled from three-ways connectors 1, rims, and a middle beam assembly, the three-ways connectors 1 and the rims being plastically integrally formed structures; a thermal bridge break structure 1-1 made of a PVC material is connected to outer sides of the three-ways connectors and the rims; the framework is formed as a cubic structure; the wall panel is a foamed panel 3 assembled from a panel and a plurality of external sheet metal parts, and the wall panel is fitted in the framework by shape-fitting. Specifically, the rim is formed as a stepped structure, and the wall panel is formed as a stepped panel shape-fitting with the stepped structure. Particularly, the middle beam assembly is assembled from a middle beam profile 4 and a middle beam connector 2 disposed at two ends of the middle beam profile 4 and is connected to the rim of the framework by means of a built-in fastener disposed on the middle beam connector 2.

FIGS. 8-11 illustrate a process of assembling a framework of a thermal bridge break air-conditioner tank according to the present invention. As illustrated in FIG. 8, the three-ways connector 1 and the rim profile are first assembled. Specifically, by inserting the axial protrusion of the three-ways connector 1 into the inner cavity of the rim profile, an interference fitting is achieved there between; by connections on a plurality of edge corners, the body framework of the air-conditioner tank will be completed after the insertion is completed; during the assembly process, it is not necessary to use a fastener such as a rivet. Further, a plurality of thermal bridge breaks 1-1 made of PVC materials are laid at the outer side of the connected three-ways connector 1 and rims by snap-fit, e.g., a hook-shaped structure, thereby guaranteeing a thermal insulation effect of the framework.

After the connection between the three-ways connector 1 and the rim profile is completed, as shown in FIG. 9, the middle beam connector 2 and the middle beam profile 4 are connected. Specifically, the middle beam connector 2 is inserted into an inner cavity of the middle beam profile 4; the secured connection between the middle beam connector 2 and the middle beam profile 4 is implemented by interference fitting the protrusion of the middle beam connector 2 and the inner cavity of the middle beam profile 4, thereby forming the middle beam profile assembly. After the insertion is completed, as shown in FIG. 10, using a built-in fastener on the middle beam connector 2, the middle beam profile assembly may be mounted on a rim framework, preferably, but not limited to, vertically mounting the middle beam profile assembly, thereby completing the assembly of the body framework of the air-conditioner tank.

Finally, in FIG. 11, the wall panel formed by the foamed panel 3 is disposed in the framework by shape-fitting, wherein the stepped panel of the foamed panel 3 matches with the stepped structure of the rim. By engaging a plurality of faces of the framework, the tank is completely sealed, thereby completely assembling the air-conditioner tank.

FIG. 12 also illustrates a variation of the three-ways connector 1. Specifically, the three-ways connector 1′ is integrally formed by a plastic material. Different from the three-ways connector 1, the three-ways connector 1′ eliminates the protrusions on the axial directions of X, Y, and Z; instead, 3 raised portions 2′ are provided on the axial directions of X, Y, and Z, respectively; the interference fitting between the three-ways connector 1′ and the rim profile are implemented using a plurality of raised portions 2′.

FIGS. 13-14 also illustrate some variations of snap-fitting between the rim profiles inside the thermal bridge break 1-1′ made of the external PVC material. As illustrated in FIG. 13, the thermal bridge break 1-1′ made of the external PVC material is connected to the internal rim profile by a hook portion bent inwardly. As illustrated in FIG. 14, the thermal bridge break 1-1′ made of the external PVC material is connected to the internal rim profile by a dovetail hook part.

FIG. 15 also illustrates a variation of the foamed panel 3. Specifically, instead of disposing the PVC frame strip 3 c of the foamed panel 3 outside of the outer panel 3 a as shown in FIG. 5, in this variation, the PVC frame stripe 3 c is disposed inside the outer panel 3 a, thereby avoiding degradation of the PVC frame strip 3 c under the influence of external environment.

The present invention has been described through the embodiments above. However, it should be understood that the embodiments above are only for exemplary and illustrative purposes, not intended to limit the present invention within the scope of the embodiments as described. Besides, those skilled in the art may understand that the present invention is not limited to the embodiments above; more variations and modifications may also be made according to the teaching of the present invention. All of these variations and modifications fall within the scope of protection of the present invention. 

1. A thermal break system for a heating, ventilation, and/or air-conditioning (HVAC) system, comprising: a first thermal break structure configured to couple to a three-way connector that defines a vertex of a housing framework, wherein the first thermal break structure includes a first retainer configured to snap-fit with a first receiver defined along a connector outer surface of the three-way connector; and a second thermal break structure configured to couple to a beam that defines an edge of the housing framework, wherein the second thermal break structure includes a second retainer configured to snap-fit with a second receiver defined along a beam outer surface of the beam.
 2. The thermal break system of claim 1, wherein the first thermal break structure and the second thermal break structure are configured to be raised relative to the connector outer surface and the beam outer surface, respectively, to enable the thermal break system to contact a surface and to block the three-way connector and the beam from contacting the surface.
 3. The thermal break system of claim 1, wherein the first receiver is a receptacle, and wherein the first retainer is a dovetail protrusion or a hook-shaped protrusion configured to engage with the receptacle.
 4. The thermal break system of claim 1, wherein the first receiver is a hook-shaped protrusion, and wherein the first retainer is a recessed groove configured to retain the hook-shaped protrusion therein.
 5. The thermal break system of claim 1, wherein the second receiver is either a receptacle or a hook-shaped protrusion, and wherein the second retainer is either a protrusion configured to mate with the receptacle or a recessed groove configured to retain the hook-shaped protrusion therein.
 6. The thermal break system of claim 1, wherein the first thermal break structure includes: an L-shaped profile configured to contact the connector outer surface and an additional connector outer surface of the three-way connector; and an additional first retainer configured to snap-fit with an additional first receiver defined along the additional connector outer surface.
 7. The thermal break system of claim 1, wherein the second thermal break structure includes: an L-shaped profile configured to contact the beam outer surface and an additional beam outer surface of the beam; and an additional second retainer configured to snap-fit with an additional second receiver defined along the additional beam outer surface.
 8. The thermal break system of claim 1, wherein a first outer surface of the first thermal break structure is configured to protrude from the three-way connector by a first distance, and wherein a second outer surface of the second thermal break structure is configured to protrude from the beam by a second distance that is substantially equal to the first distance.
 9. The thermal break system of claim 8, wherein the first outer surface of the first thermal break structure and the second outer surface of the second thermal break structure collectively define a stepped receiving ledge configured to receive an insulated panel of the housing framework.
 10. The thermal break system of claim 1, wherein the first thermal break structure and the second thermal break structure each define a respective hollow channel therein.
 11. An air-conditioner unit housing, comprising: a housing framework including a plurality of beams extending between a plurality of three-way connectors, wherein the plurality of three-way connectors defines vertices of the housing framework, the plurality of beams defines edges of the housing framework, each beam of the plurality of beams includes a beam receiver defined along a beam outer surface, and each three-way connector of the plurality of three-way connectors includes a connector receiver defined along a connector outer surface; a plurality of connector thermal break structures coupled to the plurality of three-way connectors, wherein each connector thermal break structure includes a connector retainer snap-fit with the connector receiver of a respective three-way connector of the plurality of three-way connectors; and a plurality of beam thermal break structures coupled to the plurality of beams, wherein each beam thermal break structure includes a beam retainer snap-fit with the beam receiver of a respective beam of the plurality of beams.
 12. The air-conditioner unit housing of claim 11, wherein the plurality of connector thermal break structures and the plurality of beam thermal break structures are raised relative to the connector outer surfaces and the beam outer surfaces, respectively, to separate the housing framework from a surface on which the air-conditioner unit housing is disposed.
 13. The air-conditioner unit housing of claim 11, wherein the plurality of connector thermal break structures includes four connector thermal break structures coupled to selected three-way connectors of the plurality of three-way connectors that are disposed within a common plane of the housing framework, and wherein the plurality of beam thermal break structures includes four beam thermal break structures coupled to selected beams of the plurality of beams that extend between the selected three-way connectors of the plurality of three-way connectors.
 14. The air-conditioner unit housing of claim 11, wherein each three-way connector of the plurality of three-way connectors includes a unitary connector structure having a center portion and three protrusion parts, each protrusion part extending along a respective axial direction from the center portion, wherein each protrusion part is interference fitted within an end of a respective beam of the plurality of beams.
 15. The air-conditioner unit housing of claim 11, wherein the connector retainer of each connector thermal break structure is a linear hook, an L-shaped hook, or a dovetail shaped hook.
 16. The air-conditioner unit housing of claim 11, wherein the connector retainer of each connector thermal break structure is one of a hook or a groove, wherein the connector receiver of the respective three-way connector is the other one of the hook or the groove.
 17. The air-conditioner unit housing of claim 11, comprising a wall panel interference fitted into the housing framework, wherein the wall panel includes insulation disposed therein.
 18. The air-conditioner unit housing of claim 11, wherein the plurality of connector thermal break structures and the plurality of beam thermal break structures each define a plurality of insulating hollow channels therein.
 19. The air-conditioner unit housing of claim 11, comprising a middle beam assembly extending between two opposing beams of the plurality of beams, wherein the middle beam assembly includes: a first middle beam connector coupled to a first opposing beam of the two opposing beams via a first fastener extending between a first receptacle of the first middle beam connector and the first opposing beam; a second middle beam connector coupled to a second opposing beam of the two opposing beams via a second fastener extending between a second receptacle of the second middle beam connector and the second opposing beam; and a middle beam interference fitted between the first middle beam connector and the second middle beam connector.
 20. A thermal break air-conditioner unit housing, comprising: a housing framework including a plurality of beams extending between a plurality of three-way connectors; a plurality of first thermal break structures configured to couple to the plurality of three-way connectors, wherein each first thermal break structure includes a connector retainer configured to snap-fit with a connector outer surface of a respective three-way connector of the plurality of three-way connectors; and a plurality of second thermal break structures configured to couple to the plurality of beams, wherein each second thermal break structure comprises a beam retainer configured to snap-fit with a beam outer surface of a respective beam of the plurality of beams; wherein the plurality of first thermal break structures and the plurality of second thermal break structures are each configured to be raised relative to the connector outer surface of the plurality of three-way connectors and the beam outer surface of the plurality of beams, respectively, to separate the plurality of three-way connectors and the plurality of beams from a surface on which the thermal break air-conditioning unit housing is positioned.
 21. The thermal break air-conditioner unit housing of claim 20, wherein the connector retainer of each first thermal break structure is a linear hook, an L-shaped hook, or a dovetail-shaped hook configured to mate with the connector outer surface of the respective three-way connector.
 22. The thermal break air-conditioner unit housing of claim 20, wherein the beam retainer of each second thermal break structure is a linear hook, an L-shaped hook, or a dovetail-shaped hook configured to mate with the beam outer surface of the respective beam.
 23. The thermal break air-conditioner unit housing of claim 20, wherein each three-way connector of the plurality of three-way connectors is a unitary structure constructed via injection molding.
 24. The thermal break air-conditioner unit housing of claim 20, wherein each beam of the plurality of beams is configured to be interference-fitted over an axial protrusion of the respective three-way connector.
 25. The thermal break air-conditioner unit housing of claim 20, wherein each beam of the plurality of beams includes a panel-receiving recess having a beam geometry defined along a respective length of each beam of the plurality of beams, and wherein the thermal break air-conditioning unit housing includes a wall panel having panel edges with a panel geometry configured to mate with the beam geometry of the panel-receiving recess.
 26. The thermal break air-conditioner unit housing of claim 25, wherein the wall panel includes an insulating portion at a center portion of the wall panel and a quadrangular ring at a periphery of the wall panel, wherein the quadrangular ring includes the panel geometry. 